STATION 1: Placement of Elements / Infeed Transport

The door elements are placed on the tilting table, from where they are fed to the adhesive tape application centre. At that station, the operator prepares the door elements for the subsequent process steps. The conveyor belt of the tilting table ensures that all the elements are moved gently, irrespective of the characteristics of their materials.

STATION 2: Optional Application of Glue

As an option, an additional applicator head may be fitted to the cross beam for the application of glue. The application of an adhesive to glue the glass motifs or sheet metal parts would thus be conceivable.

The main component of the gluing station ist the dosing unit specially developed by LEMUTH. Barrel pumps deliver the glue to the dosing unit, where the glue pressure is lowered by pressure reducers, with the optimum mixing ratio of the two components subsequently set via servormotor-driven gear pumps. Since the glue pressure is reduced before the glue reaches the gear pumps, the pumps operate with virtually no wear. At the optimum ratio, the two components are then delivered to the applicator nozzle, where they are mixed.

All the types of glues may be applied, such as

one-component adhesives

two-component adhesives

silicons.

A nozzle-cleaning unit ensures a perfect gluing result.

STATION 3: Turning unit

The turning unit handles the transport of both the frame and the outer panel and turns the inner panel. Before being turned, the inner panel is moved into the correct position, then suction lifted by the turning unit and turned 180 degrees to the opposite side. It is in this condition that the inner panel is transferred to the vacuum suction unit. To ensure optimum reception and transfer from the upstream to the downstream station, the turning unit is equipped with a traversing unit.

STATION 4: Vacuum Suction Unit

The suction gantry carrying the suction cups is freely movable in the x-y-direction. The suction cups attached to the suction gantry can be individually controlled and moved to the extent required. The control system allows the suction cups to be individually activated. Thanks to this dynamic activation feature, it is possible to accommodate a wide variety of situations that may arise in the front door production process.

STATION 5: Clamping Table

The clamping table is a high-precision assembly unit. Frames are positioned on the clamping table, where their exact dimensions are determined and where they are prepared for vacuum suction lifting.

The following outer panel is also accurately fixed to the horizontal clamping table, with the exact dimensions of the panel determined in order to ensure that the frame is put in place aligned in a centred way. In a last step, the outer panel - complete with the frame, glass and insulation material - is realigned and measured on the clamping table, so that the inner panel can be put in place aligned in a centred way.

STATION 6: Manual Assembly Workplace

The manual assembly workplace is equipped with a motorized conveyor belt. At this station, the insulating panels and glass panes are mounted manually. Additionally, further manual operations can be performed on the outer panel, with the frame mounted. Enhanced security monitoring and communication pushbuttons facilitate work.

STATION 7: Pressing / Curing / Removal

Once the door leaf has been accurately put together from the three parts, namely, the other panel, the frame and the inner panel, the door leaf is moved along the manual assembly table to a pressing station. In that pressing station, the parts are joined together at a definable contact pressure and pressed together by the addition of heat to become a finished door leaf. This door element can then be removed from the line.

Production Process

Frame Processing

STATION 1

On the tilting table, the frame is raised to a vertical position, with the outer side resting directly on the rear wall.

Primer is applied manually.

STATION 2

The frame is fed into the automatic adhesive tape application machine.

A double-sided adhesive tape is applied all around the frame (to the inner side of the frame).

The liner is not peeled off!

STATION 3/4/5

The frame travels on to the clamping table, where it is aligned and lifted by the vacuum suction unit to remain in that position.

Outer Panel Processing

STATION 1

On the tilting table, the outer panel is raised to a vertical position, with the outside resting directly on the rear wall.

Primer is manually applied to the outer sides and possibly existing glass motifs, so that an adhesive tape can be applied later.

STATION 2

The outer panel is fed into the automatic adhesive tape application machine.

All-around application of doubled-sided adhesive tape (approx. 0,2mm to 0,3mm in thickness) and removal of the liner.

Application of approx. 3mm thick doubled-sided adhesive tape around the glass motifs, with the liner not removed.

STATION 3/4/5

The outer panel moves to the clamping table, where it is accurately aligned and clamped. The frame positioned over it by the vacuum suction unit is accurately aligned over the outer panel, deposited onto the outer panel and pressed into position. The conveyor side represents the zero edge for the alignment of the frame and the outer panel.

STATION 6

From the clamping table, the outer panel, with the frame put in place, moves to the manual assembly workplace:

Application of glue to the outer panel with the aid of a roller

Placement of the foam panel onto the outer panel

Application of glue to the foam panel and the frame with the aid of a roller

Removal of the liner from the adhesive tape around the glass motifs

Insertion of the glass elements

Removal of the liner from the adhesive tape running around the frame

STATION 5/6

With the frame put in place, return of the outer panel to the clamping table for the placement of the inner panel.

Inner Panel Processing

STATION 1

On the tilting table, the inner panel is raised to a vertical position.

The primer is applied around the glass motifs and all around the panel. The outer side rests directly on the rear wall (below)

STATION 2

The inner panel runs on the automatic adhesive tape application machine. A single-sided adhesive sealing tape is applied all around the outside and the glass motifs. The liner is peeled off automatically.

STATION 3/4/5

The inner panel is turned at the turning station. The outer side faces upward now, with the adhesive tape side facing downward.

The inner panel is aligned and transferred to the vacuum suction unit. The vacuum suction unit receives the inner panel directly from the turning unit, without the inner panel being deposited on the clamping table in that process.

Once the outer panel, complete with the frame, has travelled back to the frame and pressed into position.

Finisching the Door Leaf

STATION 5/6/7

When the door leaf is fully assembled, it moves from the clamping table to the manual assembly workplace and from there to a subsequent heated pressing station, where the glue is cured.